Reciprocating head press

ABSTRACT

A press for flattening dough pieces is provided having a floor supported frame, an endless conveyor belt movably carried on the frame and presenting an upper horizontal surface, and at least one movable platen carried on the frame for pressing the dough pieces against the belt. In an embodiment, a sub frame is adjustably supported by the frame to permit leveling and adjustment of said sub frame relative to the frame. Attachment mechanisms are provided for securing the sub frame to the main frame following adjustment between the two. In an embodiment, at least two movable platens are carried on at least one of said frames, both of the platens being movable in a longitudinal horizontal direction and at least one of the platens is movable in a vertical direction. A linear actuator is drivingly connected to the two movable platens. In an embodiment, a loading system for loading dough balls onto the belt is provided. The loading system includes a transport mechanism to receive dough balls in a sequential stream and to deliver the dough balls to the belt at a speed equal to a speed of the belt. In an embodiment, a belt splicing hot press is carried on the frame operatively engageable with the belt to splice together severed ends of the belt to form a continuous endless belt.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to presses used to flattendough-like material, for example edible dough materials used intortillas, pizzas and similar food items.

[0002] Presses for dough material are well known and one type comprisesa stationary press in which individual dough pieces are placed under avertically movable platen, the platen compresses and spreads out thedough and then the platen is moved away revealing a flattened doughpiece which must be manually removed. Another type is an automated doughpress which typically comprises a moving belt and a verticallyreciprocating platen. Generally the belt is stopped, and while stoppedthe platen, moves downwardly to engage and flatten a dough piece againstthe belt and then the platen moves upwardly. Subsequently the beltindexes to the next position to present a new series of dough pieces tothe platen. While such an operation greatly increases the speed at whichthe dough pieces can be flattened into disks, such as tortillas andpizza crusts, the intermittent movement of the belt places a restrictionon the speed at which the overall operation can be carried out, and thestarting and stopping of the belt causes other difficulties relating totiming, energy requirements, wear and tear on the equipment as well asmovement of the dough pieces relative to the belt.

[0003] A third approach to flattening dough pieces utilizes acontinuously moving belt carrying the dough pieces and a rollerpositioned above the belt which engages and rolls out the dough onto themoving belt. While this arrangement allows for continuous movement ofthe belt, and so avoids the problems associated with intermittentoperation of the belt, this approach creates its own problems, forexample, the resulting dough pieces typically are not circular, butrather are oblong in shape, which are not as aesthetically pleasing fortortillas and pizzas. A raised rim, such as is used in pizza crusts,cannot be formed with this method and the dough itself respondsdifferently when it is rolled out, as opposed to being pressed, whichcan affect the subsequent cooking of the dough. Finally, while the doughpiece is being rolled out, the contact time between the roller and thedough itself is very brief which prevents the use of heat to conditionthe dough as it is being flattened, thus requiring an additional step ifheat is to be applied.

[0004] A fourth approach to flattening dough pieces utilizes acontinuously moving belt for receiving and carrying the dough piecesinto the press area and from the press area to a point of furtherutilization. Vertically reciprocating platens are used to press thedough pieces into flattened shapes and the platens can be heated so asto provide heat into the dough product.

[0005] To allow both a vertically reciprocating platen and acontinuously moving belt, the platens themselves are horizontallyreciprocating such that as they move together and press the dough piecesonto the belt, the platens will be moving in the same direction and atthe same speed as the belt itself. When the step of pressing, andoptionally heating, is completed, the platens will move away from thebelt and will be moved linearly backwards relative to the motion of thebelt to be in position over a new set of dough pieces to be flattened.At this point the platens will reverse direction again and willaccelerate up to the same speed in the same direction as the belt whilethe pressing occurs again.

[0006] Such an arrangement is shown in U.S. Pat. Nos. 4,938,126 and5,006,358, both to Rubio, et al. In this parent and division patentthere is disclosed a reciprocating press for making tortillas from doughballs in which various of the moving components are mechanically“slaved” to the press drive to control the timing of their respectiveactions. That is, the reciprocation movement of the press is controlledthrough a crank arm, cam and follower arrangement driven by the beltmotor. The arrangement for controlling the speed of the feed mechanismis not disclosed.

[0007] U.S. Pat. No. 5,388,503 to Berkel discloses a reciprocating pressfor forming tortillas from dough balls in which the reciprocatingmovement of the press is achieved by a direct mechanical linkage to thedrive for the conveyor belt. No feeding mechanism is disclosed forloading the dough balls onto the moving press belt.

SUMMARY OF THE INVENTION

[0008] The present invention provides an apparatus and method forflattening dough pieces which combines the advantages of pressing thedough to obtain circular or other desired shapes, allows for heating thedough while pressing, allows for continuous operation, and particularlyof the belt carrying the dough pieces, and avoids the problemsassociated with various approaches known in the art.

[0009] In one embodiment of the invention, a dough loading apparatus isprovided to deposit dough balls precisely onto a moving belt, at thesame speed as the moving belt to avoid the necessity of flattening thedough balls to prevent their movement relative to the belt.

[0010] In an embodiment of the invention, a dough ball guide tube isprovided with an ejection arrangement to prevent the passage of doubleddough balls from a proofer to be transported through the press.

[0011] In an embodiment of the invention, a sensor is provided to detectjamming of dough within the dough ball feeder.

[0012] In an embodiment of the invention, an independent dough loadingapparatus is provided which can be quickly and precisely aligned andjoined to the press and which can be removed and replaced with adifferent sized dough loading apparatus without the need for specialtools or time consuming disassembly and re-assembly operations.

[0013] In an embodiment of the invention, the press is supported by anarch style H-frame assembly to provide enhanced strength and stabilityfor the moving upper platen.

[0014] In an embodiment of the invention, a die plate is carried on theupper and/or lower platen which is removable for replacement, cleaningor repair and which can be quickly released from the platen without theuse of special tools.

[0015] In an embodiment of the invention, the vertically reciprocatingplaten is restrained against rotation.

[0016] In an embodiment of the invention, the reciprocating platens aresecurely held in a level orientation during their horizontal movement.

[0017] In an embodiment of the invention, a linear actuator and linearguides and support systems are used for reciprocating the press platens.

[0018] In an embodiment of the invention, a conduit and cable managementsystem is provided for electrical and hydraulic lines extending betweenthe reciprocating press components and the stationary frame components.

[0019] In an embodiment of the invention, a belt splicing hot press unitis provided for repair and replacement of the main conveyor belt of thepress.

[0020] In an embodiment of the invention, the linear actuator is servodriven to control the position, acceleration and speed of thereciprocating press platens.

[0021] In an embodiment of the invention, a brush roller is used in atransfer of tortillas from the press belt to a discharge belt.

[0022] In an embodiment of the invention, dual drive rollers, withurethane coating, are used to drive the press belt.

[0023] In an embodiment of the invention, various components of thepress are carried on a sub-frame which is independently levelablerelative to a main frame carried on a supporting surface.

[0024] In an embodiment of the invention, jack screws are provided foran independent leveling of a sub-frame assembly.

[0025] In an embodiment of the invention, the linear guide elements arecarried on a sub-frame independent from a main frame of the press.

[0026] In an embodiment of the invention, a single controller is used tocoordinate the various movements of each of the components of the presssystem.

[0027] In an embodiment of the invention, the controller controlsmultiple zones of the platens with respect to their temperature.

[0028] In an embodiment of the invention, the movement of the press iscoordinated with movement of other components in a dough processingsystem.

BRIEF DESCRIPTION OF T HE DRAWINGS

[0029]FIG. 1 is a schematic side elevation view of a dough processingsystem incorporating a press embodying the principles of the presentinvention.

[0030]FIG. 2 is a block diagram of a control system for the pressembodying the present invention.

[0031]FIG. 3 is a side elevational view of the press embodying thepresent invention.

[0032]FIG. 4 is a detailed side elevational view of a loading system forthe press of FIG. 3.

[0033]FIG. 5 is an isolated side elevational view of a portion of theloading system of FIG. 4.

[0034]FIG. 6 is a plan view of a portion of the loading system of FIG.4.

[0035]FIG. 7 is a partial side elevational view of the press of FIG. 3.

[0036]FIG. 8 is a partial end elevational view of the press of FIG. 3.

[0037]FIG. 9 is a partial plan view of the press of FIG. 3.

[0038]FIG. 10 is a partial side elevational view of the upper platensupport frame.

[0039]FIG. 11 is a partial end elevational view of the upper platensupport frame taken 90 degrees from the view of FIG. 10.

[0040]FIG. 12 is a plan view of the upper platen support frame.

[0041]FIG. 13 is a partial end elevational view of the platens and theirsupport structure.

[0042]FIG. 14 is a partial plan view of the platens and their supportstructure.

[0043]FIG. 15 is a detail side elevational view of a guide assembly forthe upper platen.

[0044]FIG. 16 is a side elevational view of the hot splice press used onthe press of FIG. 3.

[0045]FIG. 17 is a partial side elevational view of the drive area forthe press belt.

[0046]FIG. 18 is a partial side elevational view of the drive area forthe press belt.

[0047]FIG. 19 is a partial cross sectional view of the linear guide andhold down assemblies.

[0048]FIG. 20 is a plan view of the hose deck area of the press of FIG.3.

[0049]FIG. 21 is a partial side elevational view of the discharge areafor the press belt.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] A. Overview

[0051] The present invention relates to a press 400 for flattening doughpieces, for example, flattening dough balls into pancake like shapes fortortillas, pizza crusts and similar food products. Because of the highrates of product through the press, the press is typically arranged in asystem 100 of mechanisms as illustrated schematically in FIG. 1. Thissystem can begin with a dough mixer 102 in which flour, corn meal orsimilar product is mixed with water and other ingredients according tosome particular recipe to produce a large batch of dough. The mixer mayinclude an elevator 104 to raise a portion of the mixer to an elevatedposition where the mixed dough batch is dropped into a holding hopperand dough chunker 106. In the holding hopper and dough chunker 106 thebatch of dough is held and then chunks of dough are dispensed into adough divider and rounder 108 in which the dough is divided into muchsmaller portions and is rounded into ball shapes. The rounder 108 thenfeeds individual dough balls to a proofer 110 where the dough balls areheld at a predetermined temperature and humidity for a prescribed lengthof time, such as by moving along a conveyor traveling through theproofer where the dough balls are held in individual pockets or trays inthe proofer. At the end of the proofing time, a series of dough ballsare dispensed through a dough loading apparatus 300 to the press 400,such as the press incorporating the principles of the present invention.In the press 400, the individual dough balls are pressed between movableplatens while the dough balls are carried on a continuously movingconveyor belt, all as described in more detail below. When the doughballs have been flattened into pancake-like shapes, they are dispensedfrom the end of the press 400 to an oven 112 where the dough productsare partially or fully baked. Following the baking process, the doughpieces move on a conveyor 114 to a cooling conveyor 116 from where theyare moved to a packing system 118 or storage area.

[0052] B. Control System

[0053] Preferably a single control system 200, as shown schematically inFIG. 2, is utilized to control all of the different functions, movementsand operations of the reciprocating press 400 and including the doughloading apparatus 300. A programmable logic controller 202 or PLC can beused to operate various motors of the system and preferably several ofthe motors are servo motors so the speed and angle of rotation of themotor drive shafts can be controlled precisely. A motor 204, preferablya servo motor, is used to regulate the loading speed of the doughloading apparatus 300. A motor 206, preferably a variable speed motor,is used to move the belt 602 which carries the dough pieces. A motor208, again preferably a servo motor is utilized to operate a linearactuator to move the press platens in a reciprocating fashion in thedirection of the belt movement. A motor 210, preferably a variable speedmotor, is used to drive an out feed conveyor and an unloading roller.The timing and operation of each of these motors must be orchestratedvery carefully with respect to each other, as well as with respect toother mechanisms in the system 100 to maintain a steady flow of doughproduct through the system 100.

[0054] The controller 202 is provided with a number of inputs. A firstsensor 212, which preferably is an encoder, is utilized to sense thespeed of the proofer 110 and this sensed speed is provided to thecontroller 202 so that the speeds of the various other components can beadjusted accordingly as product from the proofer 110 is delivered to thedough loading apparatus 300 and the reciprocating press 400. A sensor214, which may be in the form of an encoder, provides a signal to thecontroller 202 with respect to the speed of the belt 602 so thatdelivery of the dough balls by the dough loading apparatus 300 arespaced accurately onto the belt. An input device 216, which may be akeyboard, a touch screen, or other known input devices, is provided tothe controller 202 to allow entry of various information including thesize and placement of the dough pieces to be pressed, the pressure towhich the dough pieces are to be pressed, the dwell time for the platensto be held in their closest position, the temperature at which theplatens should be maintained, and other operating variables. At leastone temperature sensor 218 is provided which is associated with theplatens to measure a temperature at the platens and to provide thatinformation to the controller 202. In an embodiment of the invention, aplurality of temperature sensors 218 are provided which sense thetemperature of different zones of the platens for better maintenance andcontrol purposes. A sensor 220 is used to determine a “full down”position for the upper press platen. A sensor 222 is used to detect any“clogs” in an in-feed tube of the dough loading apparatus 300. A sensorarrangement 224 is used to “home” the platens in a horizontal direction.A sensor 226 is used to “home” the dough loading apparatus 300. Heatingelements 228 in the platens are controlled by the controller 200. Adisplay device 230 is provided to provide a visual and perhaps audibledisplay of the operation of the press and system for operation andcontrol.

[0055] C. Dough Loading Apparatus

[0056] In FIG. 3 there is illustrated a reciprocating press generally at400 as well as a dough loading apparatus 300. A dough feeding device 302is provided to feed dough in the form of dough balls 304 to the doughloading apparatus 300 (shown in greater detail in FIGS. 4-6). The doughfeeding device 302 in turn may receive dough balls 304 from the proofer110 in which the formed dough balls have been carried for a length oftime at a prescribed temperature and humidity level to allow the doughto proof. The dough balls 304 are fed from the proofer 110 through thedough feeding device 302, which may comprise a series of drop tubes 306in which dough balls drop into a receiving inlet 308 (shown in greaterdetail in FIG. 5), at a predetermined rate. The dough receiving inlet308 may be in the form of a truncated cone or funnel shape to assist inguiding individual dough balls 304 into the dough loading apparatus 300.The inlet 308 to the dough loading apparatus 300 leads to one or morevertical guide tubes 310. The tubes 310 may have a circular, square orother shaped cross section and extend downwardly and terminate justabove a rotatable pocket wheel 312.

[0057] The drop tubes 306 of the dough feeding device 302 typically arehinged near their top to swing away from the inlet 308 of the doughloading apparatus 300 for cleaning and other maintenance purposes. Toassure a proper placement of a lower end 314 of the drop tube 306relative to the funnel inlet 308, a drop tube receiver and guide 316 maybe mounted above the inlet 308. The tube receiver and guide 316 has aU-shaped opening 318 (FIG. 6) to receive and precisely locate the lowerend 314 of the drop chute 306. The drop tube receiver and guide 316 ismounted on legs 320 above a flange 322 at the top end of the inlet 308.In this manner, the material utilized for the drop tube receiver andguide 316 can be kept at a minimum while accommodating the swing of thedrop tubes 306 which require their lower ends 314 to be spaced above theflanged top of the inlet funnel 308. The drop tube receiver and guide316 can be formed of a light weight and inexpensive material, such asU.H.M.W. plastic.

[0058] The guide tubes 310 may be provided with an opening or cut out324 (FIG. 5) positioned just above the pocket wheel 312 to allow for theejection of a potential upper dough ball of a double dough ball whichhas fallen through the guide tube 310. Occasionally two dough balls mayget stuck together in the proofer 110 and may fall together through thedrop tubes 306. In order to prevent the double ball from continuing oninto the press 400, the opening 324 permits the uppermost dough ball tobe ejected during the loading process. The lower dough ball drops intoone of several pockets 326 a-d formed in an outer periphery of thepocket wheel 312. The pocket wheel 312 is rotated about an axis 328 bymeans of the motor 204 connected to the pocket wheel 312 by means of abelt drive 330, such as a timing belt. The pocket wheel 312 is driven ina counter clockwise direction, as seen in FIG. 5, so that the dough ball304 received in the uppermost pocket 326 a will move to the left. If asecond dough ball is captured on top of the dough ball in the pocket 326a, the second dough ball will move out of the guide tube 310 through thesidewall opening 324, leaving the guide tube empty to allow the nextdough ball 304 to drop down to the next pocket. The sensor 222, whichmay be a diffused type photoelectric sensor, can be placed in the guidetube 310, spaced above the lower end 314 of the guide tube, to sense forproduct jamming. For example, if the sensor 222 detects a blockage whichcontinues beyond some set period of time, measured in seconds orportions thereof, the controller 202 may cause an alarm to sound and, ifthe sensed blockage continues for a further length of time, measured inadditional seconds, the controller 202 could stop the entire press 400.

[0059] The opening 324 in the guide tube 310 can be adjusted in size bythe use of vertically adjustable sliding door 332. This allows theentire loading apparatus 300 to be able to be used with different sizeddough balls and to accommodate allowing ejection of large dough balls,when large dough balls are being fed through the apparatus, yetpreventing too large an opening when small dough balls are being fedthrough the apparatus, which might otherwise lead to improper ejectionof the small dough balls. When the opening 324 is provided, it ispreferable to form the guide tube 310 with a square cross section. Thisway the opening 324 takes up no more than one fourth of the perimeter ofthe guide tube 310, thereby maintaining the strength and integrity ofthe guide tube. The door 332 may also be hinged and held closed by alatch 325. This permits access to the interior of the guide tube 310 forcleaning and maintenance purposes.

[0060] As the dough balls (the one in the pocket and the potentialdouble dough ball) are rotated by the pocket wheel 312, they will moveto a second position in which the pocket 326 b is partially eclipsed bya dough ball retaining shoe 334. This shoe 334 will retain the properlycaptured dough ball 304 in the pocket 326 b and will cause any seconddough ball carried outside the perimeter of the pocket wheel 312 to bereleased from the pocket wheel. The released dough ball may be depositedonto a sloped ramp 336 (FIG. 4) leading to a collection zone 338 fromwhere the collected extra dough balls can be removed, either manually orvia a conveyor mechanism.

[0061] The pocket wheel 312 is indexed from one stationary position to anext stationary position by means of the motor 204 which preferably is aservo motor. The servo motor receives speed information relating to thecontinuously moving belt 602 of the press 400 such that the pocket wheel312 will accelerate from each stationary position to the then currentbelt speed before it decelerates again to the next stop position. Thestarting and stopping positions, the acceleration and decelerationrates, as well as the top speed (which should equal the belt speed) caneach be controlled by the controller 202 when the motor 204 is a servodrive motor.

[0062] In the embodiment illustrated in FIG. 5, the pocket wheel 312 hasfour stations, each positioned at 90° to the other around the peripheryof the pocket wheel. The uppermost pocket station 326 a is positioneddirectly below the guide tube 310 for receiving the dough ball 304 fromthe guide tube. The lowermost pocket station 326 c has the retainingshoe 334 still eclipsing at least a majority of the opening of thepocket 326 c such that the dough ball 304 in the lowermost pocketstation 326 c of the pocket wheel 312 will be captured by the retainingshoe 334 while the uppermost pocket station 326 a waits to receive a newdough ball 304. When the pocket wheel 312 next accelerates to beltspeed, the lowermost dough ball in the lowermost pocket station 326 cwill be accelerated to the belt speed, will rotate clear of theretaining shoe 334 and will drop vertically onto the belt 602 at beltspeed, thereby assuring that the dough ball 304 will maintain itsposition on the moving belt without rolling. The pocket wheel 312 willcontinue to rotate through 90° allowing the released dough ball 304 tomove away from the pocket wheel without interference. The fourth station326 d is clear of the shoe 334 and should be empty of the dough ball 304which has now been deposited on the belt 602. In this manner, the doughball can be precisely placed onto the belt 602 such that a spacing 340between adjacent dough balls 304 on the belt can be preciselycontrolled. The dough balls 304 will also be placed onto the belt 602without rolling, so that the dough balls will maintain their position onthe belt, even without any flattening of the dough balls as is requiredin intermittently operated presses.

[0063] As seen in FIG. 4, the entire dough loading apparatus 300 iscarried on a frame 342 which may be completely independent from thereciprocating press 400 and can be mounted on separate wheels 344 toallow the dough loading apparatus 300 to be selectively used andpositioned relative to the press 400 as desired. The frame 342 can bewider than the belt 602 to permit the frame to straddle the belt andthereby overlie an end of the belt. A plurality of locking pins 346 (oneeach lateral side of the frame 342) can be received in sleeves 348carried on the dough loading apparatus frame 342 and further received inpockets 350 secured to a frame component 352 of the reciprocating press400 to hold the dough loading apparatus 300 in a precise alignmentposition with the reciprocating press 400. Dough loading apparatus 300which can accommodate differing sizes of dough balls 304, such as withdiffering sized pocket wheels 312 or pockets 326, thereby can be quicklymoved into position relative to the press 400 to change over a line toproduce different sized dough pieces as necessary.

[0064] D. Frame Construction and Press Movement

[0065] The dough balls 304 carried on the belt 602 are to be pressedinto flat pancake like shapes when the press 400 is being operated toform tortillas, pizza crusts and similarly shaped food items. Toaccomplish this, as shown in FIG. 3 the press 400 includes an upperplaten 430 and a lower platen 426 which can reciprocate toward and awayfrom each other to vary an open space therebetween. The two platens 426,430 can move toward each other a sufficient amount to engage the doughballs 304 and to flatten them to a desired thickness and then to moveaway from one another to allow a new set of dough balls to be placedtherebetween. Also, both the upper platen 430 and the lower platen 426can reciprocably move longitudinally relative to the press 400, that is,in the direction of the moving belt 602, such that while the platens areengaging and pressing the dough balls 304, the platens move in the samedirection and at the same speed as the moving belt thereby allowing thebelt to continue in its movement without slowing or stopping.

[0066] In an embodiment, the reciprocating press 400 comprises a baseframe 402 (FIG. 3) which can be secured to a floor or other mountingsurface as well as a sub-frame 404 which carries operative components ofthe press. The sub-frame 404 can be secured to, but adjustedindependently of the base frame 402 to allow for precise leveling of theoperative components in order to eliminate any vibration caused by themoving components of the press 400. A plurality of jack screws 406provide the adjustable attachment between the two frames and provide fora plurality of points of adjustment between the two frames, bothlaterally and longitudinally. Once the sub-frame 404 has been adjustedrelative to the base frame 402, the two frames can be securely attachedto each other through the use of suitable attachment mechanisms, such asthreaded fasteners at mounting plates 407. Alternatively, a single mainframe can be utilized with all components secured to the main frame.

[0067]FIGS. 7, 8 and 9 illustrate the sub-frame 404 and the componentscarried on the sub-frame. The sub-frame 404 is comprised of arectangular assembly comprised of two longitudinal frame beams 408 and aplurality of lateral frame beams 410. A mounting plate 412 is secured toone of the lateral beams 410 and an end 414 of a linear actuator 416 issecured to the mounting plate 412. The linear actuator 416 includes anextendable and retractable piston 418 which is secured to a mountingplate 420 which is, in turn, secured to a downwardly depending wall 422of a carriage 424. The carriage 424 has secured to it the lower platen426 as well as a support frame 428 for the upper platen 430. The supportframe 428 includes four vertical posts 432 which carry an H-frameassembly 434 for supporting a hydraulic cylinder 436 which includes anextendable and retractable piston 438 to which is secured the upperplaten 430.

[0068] The carriage 424 is supported on a pair of linear rails 440mounted directly to the longitudinal beams 408 of the sub-frame 404.Four sets of linear guide bearings 442 (FIG. 8) are carried on thecarriage 424 to engage the linear rails 440. In a preferred embodiment,the guide rails 440 are cylindrical bars supported above thelongitudinal frame beams 408. Two linear roller bearings 442 a (frontand back) engage with one rail 440 a (FIG. 19). Two sets of two angledlinear roller bearings 442 b and 442 c (front and back) engage with theother guide rail 440 b as shown in FIG. 8. In this manner, the carriage424 will be carried along the guide rails 440 in a linear fashion andwill be restrained against any lateral movement.

[0069] A plurality of mounting plates 407 are secured to the sub-frame404 and are used to secure the sub-frame 404 to the base frame 402 oncethe sub-frame 404 has been rendered level. Thus, the entire sub-frame404 and all of the components carried thereon can be precisely leveledand aligned, independent of the base frame 402 and then the sub-frame404 can be securely attached to the base frame and held in thehorizontal and aligned position.

[0070] The support posts 432 for the H-frame 434 are secured to thecarriage 424, for example, by appropriate fasteners 446. The H-frame 434is carried on the posts 432 by threaded rods 448 which can beindependently adjustable at each post 432 to allow the H-frame 434 to beprecisely leveled and aligned. The threaded rods 448 carry locking orjamming nuts 450 to bold the position of the H-frame 434 relative to theposts 432 once the precise leveling and alignment has occurred. In thismanner, future adjustments to the leveling of the H-frame 434 and themovable upper platen 430 can be carried out quickly and precisely byrotation of the various nuts 450 as required.

[0071] The H-frame 434 is shown in greater detail in FIGS. 10-12 whereit is seen that the frame assembly comprises a pair of arch shapedvertical outer plates 452 to which are secured, such as by welding, apair of arch shaped vertical cross plates 454 which are, in turn,supported and stabilized by an inner pair of arch shaped vertical plates456 arranged parallel to the outer plates 452. A pair of relativelyshort end plates 458 are attached, such as by welding, to the ends ofthe inner plates 456 and extend parallel to the cross plates 454. Thus,a generally rectangular box-like frame is formed by the plates 452, 454,456, 458. Attached to each corner is a corner block 460 having avertical passage 462 therethrough for receiving the threaded rods 448.In order to reduce the weight of the H-frame assembly, various sized andplaced openings 464 can be made in the plates so long as their size andplacement does not reduce the strength and rigidity of the H-frame 434.

[0072] A sheet 466 is secured as a floor to the H-frame 434 and is alsoprovided with various shaped openings 468 to reduce its weight.

[0073] A support plate 470 is secured, such as by welding, to thevertical plates 454, 456. Secured to the support plate 470 is the doublerod hydraulic cylinder 436 having an upwardly extending threaded rod end472 and a downwardly extending threaded rod end 474. The double rodcylinder 436 can be secured to the support plate 470 by appropriatefastening means, such as threaded fasteners.

[0074] The upwardly extending threaded rod end 472 is shown in FIG. 11in an upwardly extended position and in FIG. 10 in a downwardly extendedposition. In order to prevent the upper platen 430 from damaging thebelt 602, a hard stop arrangement is provided on the upwardly extendingthreaded rod end 472. An impact pad 476 is positioned to overlie thesupport plate 470 and to surround the threaded rod end 472. Carried onthe threaded rod end 472 is an internally threaded nut 478 carrying asteel disk 480 which is permanently affixed thereto or formed integrallytherewith. The hydraulic cylinder 436 is extended downwardly so that theupper platen 430 is moved to a lowermost desired position as a safetystop position. Then, the nut 478 is threaded onto the upper threaded rodend 472 until the disk 480 engages the impact pad 476. Then a jam nut482 is threaded onto the upper extended threaded rod end 472 to jamagainst the nut 478 to prevent it from moving. In this manner, a failsafe stop position is provided to prevent over travel of the platen 430beyond the distance selected by the controller 202.

[0075] As seen in FIG. 13, a frog 484, stabilized for reciprocalmovement by a pair of nested and telescoping cylinders 486, 490 has ahorizontally extending circular flange 492 to which the upper platen 430is secured, such as by threaded fasteners. The frog 484 is also providedwith a central web 494 with an aperture therethrough for receiving thedownwardly extending threaded rod end 474. A threaded nut 496 is engagedonto the threaded rod end 474 to secure the end of the threaded rod tothe web 494, and hence the frog 484, and when the hydraulic cylinder 436extends the rod 474 downwardly, the upper platen 430 moves downwardly.

[0076] As seen in FIGS. 13 and 15, a pair of guide posts 502 areprovided which extend between the upper platen 430 and the lower platen426 to prevent any twisting movement between the platens as they arereciprocated vertically toward and away from one another. The guideposts 502 are secured in a mounting 504 in the lower platen 426 andextend up through a bushing 506 in the upper platen 430 to allow forsmooth linear movement of the guide post 502 in the bushings 506.

[0077] The upper platen 430 is provided with a removable free form dieplate 508 which can be formed of an appropriate material, such asaluminum, with a smooth, uninterrupted surface to engage the doughpieces. The die plate 508 can be secured to the platen by a clampingarrangement 510 in which a plurality of clamps are carried on the upperplaten 430 and engage laterally projecting pins 512 extending from theplate 508 so that no fasteners extend through the bottom face of theplate 508. In the course of operation of the press 400, occasionallyforeign objects are deposited on the belt 602 and when those foreignobjects are present between the two platens, when they move closelytogether under great pressure, damage to the surface of the platen couldresult, thus requiring it to be repaired. With the use of the die plate508, if the surface of the die plate becomes damaged, it can be quicklyremoved from the upper platen 430, by releasing of the clamps 510, andreplaced with a new die plate, or reversed, to use the opposite side ofthe die plate. Also, normal maintenance of the press 400 requires thatthe underside of the upper platen 430 be cleaned and by using theremovable die plate 508, the die plate itself can be easily and quicklyremoved to facilitate the cleaning process. Further, a new die plate canbe inserted and the press resume to operation while the removed dieplate is being cleaned, thereby resulting in less down time for theequipment. An identical arrangement can be used at the lower platen 426,that is, a removable and replaceable die plate, preferably secured tothe lower platen with quick release clamps.

[0078] As shown in FIGS. 3 and 20, a support deck 514 is provided tosupport hydraulic hoses and electric lines 516 which are attached at oneend to the H frame 434 and upper platen 430 and at an opposite end tosupply lines outside of the press 400. Custom hose plumes 518 are usedto hold the hoses and lines 516 in a fixed relationship to each other,yet to allow movement of the hoses and lines as the platens 426, 430horizontally reciprocate relative to the press frame 402, 404.

[0079] E. Belt Movement

[0080] A belt drive system 600 is mounted to the frames 402, 404 todrive the belt 602, preferably in a continuous fashion.

[0081] The base frame 402 includes a top sheet or deck 520 (FIG. 3)providing a flat surface on which the belt 602 moves while it receivesand first carries the dough balls 304. The belt 602 then passes betweenthe upper and lower platens 430, 426 and is supported by the verticallystationary lower platen 426. The belt 602 then passes over a second topsheet or deck 522 to the right of the platens as seen in FIG. 3. Thebelt 602 then passes over a direction changing roller 604 which is anidling roller and continues downwardly to partially wrap partiallyaround and under a first drive roller 606, then over and partiallyaround a second drive roller 608 and then continues downwardly to passunder a direction changing idler roller 610. The belt continues to theleft (as seen in FIG. 3), under the press 400, passes over a supportroller 612, then partially wraps around a direction changing idlerroller 614 and up and around and over a direction changing idler roller616 which aligns the belt with the surface of the top sheet 520 fromwhich it continues as just described. One of the rollers, and preferablythe idler roller 616, is adjustably mounted to the frame 404 such thatit can be used to provide a desired tension to the belt 602 once thebelt is assembled onto the press 400. The belt 602, thus, is an endlessbelt and moves continuously around the press 400 driven by the driverollers 606, 608.

[0082] As shown in FIGS. 17 and 18, the drive rollers 606, 608 aredriven, in opposite rotating directions, by the motor 206 whichpreferably is a variable speed drive motor whose speed can be controlledprecisely. A single chain 618 is used to drive both rollers 606, 608 toassure that their speed is identical to prevent any stretching orslipping of the belt 602. Preferably the rollers 606, 608 are urethanecoated so that the rollers will grip the belt 602 to maintain aconstant, steady motion. The ductility of the urethane also allowsexcess dough or other malible debris to pass between the rollers 606,608 without belt damage. While the preferred mode of operation would beto operate the motor 206, and therefore drive the belt 602, at aconstant speed during the press operation, the press 400 may be placedinto a system 100 with other components, such as the proofer 110described above, which may experience some variability in speed ofdelivery of dough balls, and therefore the speed of the belt may need tobe adjusted to accommodate differing speeds of other components in thesystem. The use of the variable speed motor 206 will permit thisaccommodation.

[0083] F. Dough Unloading

[0084] As seen in FIG. 21, when the flattened dough pieces pass overroller 604 where the belt 602 changes direction to a downwardlydirection, the dough pieces are engaged by an unloading system 700 wherethe undersides of the now flattened dough pieces are engaged by arotating roller 702. This roller 702 may be in the form of a nylon brushwhich is rotated with a tangential surface speed maintainedsubstantially equal to the surface speed of the belt 602 to avoiddamaging the flattened dough pieces. Optionally, an air jet device 704may be provided to direct a curtain or series of jets of air to theunderside of the flattened dough pieces. Preferably the roller 702 ispositioned directly adjacent to the roller 604 to prevent or minimizeany gap for the flattened dough pieces to drop into. The air jets 704should be directed into the space between the roller 604 and the roller702 both to help separate the dough pieces from the belt 602 and to helpsupport the dough pieces as they are suspended between the roller 604and the roller 702. When the roller 702 is provided in the form of anylon brush with nylon bristles, the air jet is able to pass through thebristles, thereby allowing the roller 702 to be positioned with thebristles in contact with the belt 602 passing over the roller 604, tominimize the gap.

[0085] A discharge conveyor belt 706 is provided on the opposite side ofthe roller 702 from the roller 604 to immediately pick up and carry theflattened dough pieces away from the press belt 602. The motor 210 isused to drive the outfeed conveyor belt 706 as well as the roller 702and the speed of the motor 210 is controlled to maintain the speed ofthe discharge conveyor belt 706 substantially equal to the speed of thepress belt 602. The discharge conveyor belt 706 extends over to aninfeed conveyor of the oven 112 so that the flattened dough pieces arecarried on into the oven for baking as described earlier.

[0086] G. Splicer Press

[0087] During the operation of the reciprocating press 400 the pressbelt 602, which is at least partially formed of plastic, such as Teflon,is subject to wear due to the continuous high pressure pressing of thepress platens 426, 430. A regular part of the maintenance and servicingof the press includes the replacement of the belt 602 which, in previouspresses, has required the disassembly of several components in order torelease the tension on the belt as well as to provide an accessible pathfor the continuous belt to be laterally moved off of the press. Thisreplacement operation typically required many hours to complete.

[0088] An optional arrangement, as shown in FIG. 16, is provided in theform of a splicing press system 800 which can be located in the area ofthe deck 522. The splicing press system 800 includes a pair of spacedapart hold down bars 802, 804 which extend laterally across the width ofthe belt 602 and which are provided with clamp arrangements 806, 808engageable with clamping tabs 810, 812 secured to the press frame 404 byappropriate means, such as welding. Positioned between the two hold downbars 802, 804 is a vertically movable splice press 814 including anelongated bar 816 which extends laterally across the width of the belt602 and which can be raised and lowered by means of hydraulic pistons818. Positioned in the deck 522 is a lower bar 820 to engage a lowerside of the belt 602. Either or both of the upper bar 816 and lower bar820 may be provided with heating elements.

[0089] When an old belt 602 is to be replaced, the belt can simply becut and threaded out of the press 400 once the tension roller 616 isreleased. A new belt 602 may be threaded around the various rollers andits free ends positioned in an overlapping manner directly between theupper bar 816 and lower bar 820 with the hold down bars 802, 804 holdingthe belt in place. The ends of the belt are then thermally weldedtogether by pressing the upper bar 816 and lower bar 820 together with asufficient pressure provided by the hydraulic pistons 818 and heat isapplied at an appropriate temperature for a sufficient length of time soas to thermally melt the Teflon® belt, thus forming an endless belt. Theupper bar 816 and lower bar 820 are then moved away from one another andthe hold down bars 802, 804 are released, the tension roller 616 ismoved to re-establish the proper tension in the belt 602 and the press400 is ready to operate. This replacement procedure reduces the timerequired for replacing of the belt from a time measured in hours to atime measured in minutes.

[0090] As is apparent from the foregoing specification, the invention issusceptible of being embodied with various alterations and modificationswhich may differ particularly from those that have been described in thepreceding specification and description. It should be understood that Iwish to embody within the scope of the patent warranted hereon all suchmodifications as reasonably and properly come within the scope of mycontribution to the art.

I claim as my invention:
 1. A press for flattening dough piecescomprising: a main frame supportable on a floor of a workplace; a subframe supportable by said main frame; adjustment mechanisms positionedbetween said sub frame and said main frame to permit leveling andadjustment of said sub frame relative to said main frame; attachmentmechanisms for securing said sub frame to said main frame followingadjustment of said sub frame relative to said main frame; a conveyorbelt formed at least partially of a plastic material movably carried onat least one of said frames and presenting an upper horizontal surfacealong at least a portion of its length; at least one upper and onelower, vertically opposed, movable platens carried on at least one ofsaid frames; both of said platens being movable in a longitudinalhorizontal direction parallel with a moving direction of said upperhorizontal surface of said belt; said upper one of said platens beingmovable in a vertical direction toward and away from said conveyor belt;a linear actuator drivingly connected to said two movable platens; aservo motor drivingly connected to said linear actuator; a carriage towhich said two movable platens are mounted; at least two linear guiderods supporting said carriage for linear movement; a loading system forloading dough balls onto said moving upper surface of said conveyorbelt; said loading system comprising a transport mechanism arranged toreceive dough balls in a sequential stream and to deliver said doughballs to said moving conveyor belt at a speed equal to a speed of saidupper surface of said conveyor belt; said transport mechanism comprisinga drop tube having an upper opening for receiving said sequential streamof dough balls, a pocket wheel positioned below an open bottom end ofsaid drop tube and above said upper surface of said conveyor belt, saidpocket wheel having a plurality of depressions in an outer circumferencethereof to receive dough balls from said drop tube, and a servo motordrivingly connected to said pocket wheel; and a belt splicing hot presscarried on said frame operatively engageable with said belt to splicetogether severed ends of said belt to form a continuous endless belt. 2.A press according to claim 1, including a control for receiving a signalindicative of a speed of said upper surface of said conveyor belt andfor generating a signal to said servo motor to control a speed of saidmotor so that said dough balls carried in said depressions of saidpocket wheel are delivered to said upper surface of said conveyor beltat a said speed of said upper surface.
 3. A press according to claim 1,including belt hold down clamps secured to said frame and engageablewith said upper surface of said belt.
 4. A press according to claim 1,wherein said belt splicing hot press comprises a vertically movableupper platen having a heating element therein and engageable with saidupper surface of said belt and a stationary lower platen having aheating element therein and engageable with a lower surface of saidbelt.
 5. A press according to claim 1, including a support frame forsaid loading system, said support frame being mounted on wheels andbeing movable relative to said main frame.
 6. A press according to claim1, including an arch style H frame carried on said carriage forsupporting said upper platen.
 7. A press according to claim 6, whereinsaid H frame carries a hydraulic cylinder with a vertically movablepiston.
 8. A press according to claim 1, wherein said movable pistonincludes an adjustable hard stop mechanism for preventing movement ofsaid piston beyond a preselected downward position.
 9. A press accordingto claim 1, including a removable free form die plate secured to a lowerface of said upper platen.
 10. A press according to claim 9 including aquick release retaining mechanism for securing said die plate to saidupper platen.
 11. A press for flattening dough pieces comprising: a mainframe supportable on a floor of a workplace; a sub frame supportable bysaid main frame; adjustment mechanisms positioned between said sub frameand said main frame to permit leveling and adjustment of said sub framerelative to said main frame; attachment mechanisms for securing said subframe to said main frame following adjustment of said sub frame relativeto said main frame; an endless conveyor belt movably carried on at leastsaid sub frame and presenting an upper horizontal surface along at leasta portion of its length; at least one movable platen carried on at leastone of said frames and positioned to compressingly engage said conveyorbelt.
 12. A press according to claim 11, wherein said at least onemovable platen comprises two movable platens and both of said platensbeing movable in a longitudinal horizontal direction parallel with amoving direction of said upper horizontal surface of said belt and atleast one of said platens being movable in a vertical direction.
 13. Apress according to claim 11, wherein said adjustment mechanisms comprisejack screws extending between said main frame and said sub frame at aplurality of positions.
 14. A press according to claim 11, wherein saidattachment mechanism comprises a plurality of threaded fasteners.
 15. Apress for flattening dough pieces comprising: a frame supportable on afloor of a workplace; an endless conveyor belt movably carried on saidframe and presenting an upper horizontal surface along at least aportion of its length; at least two movable platens carried on at leastone of said frames; both of said platens being movable in a longitudinalhorizontal direction parallel with a moving direction of said upperhorizontal surface of said belt; at least one of said platens beingmovable in a vertical direction a linear actuator drivingly connected tosaid two movable platens.
 16. A press according to claim 15, including aservo motor drivingly connected to said linear actuator.
 17. A pressaccording to claim 15, including a carriage to which said two movableplatens are mounted and at least two linear guide rods supporting saidcarriage for linear movement.
 18. A press for flattening dough piecescomprising: a frame supportable on a floor of a workplace; an endlessconveyor belt movably carried on said frame and presenting an upperhorizontal surface along at least a portion of its length; at least onemovable platen carried on said frame; a loading system for loading doughballs onto said moving upper surface of said conveyor belt; said loadingsystem comprising a transport mechanism arranged to receive dough ballsin a sequential stream and to deliver said dough balls to said movingconveyor belt at a speed equal to a speed of said upper surface of saidconveyor belt.
 19. A press according to claim 18, wherein said transportmechanism comprises a drop tube having an upper opening for receivingsaid sequential stream of dough balls, a pocket wheel positioned belowan open bottom end of said drop tube and above said upper surface ofsaid conveyor belt, said pocket wheel having a plurality of depressionsin an outer circumference thereof to receive dough balls from said droptube, and a servo motor drivingly connected to said pocket wheel.
 20. Apress according to claim 19, including a control for receiving a signalindicative of a speed of said upper surface of said conveyor belt andfor generating a signal to said servo motor to control a speed of saidmotor so that said dough balls carried in said depressions of saidpocket wheel are delivered to said upper surface of said conveyor beltat a said speed of said upper surface.
 21. A press according to claim19, including a dough ball retaining shoe positioned along acircumference of said pocket wheel.
 22. A press according to claim 19,including a chute receiver and guide mounted at said upper opening ofsaid drop tube.
 23. A press according to claim 19, including a photo eyelocated in said drop tube for detecting the presence of a dough ball insaid drop tube.
 24. A press according to claim 18, including a supportframe for said loading system, said support frame being mounted onwheels and being movable relative to said frame.
 25. A press accordingto claim 24, including attachment mechanisms for securing said supportframe to said frame.
 26. A press for flattening dough pieces comprising:a frame supportable on a floor of a workplace; a conveyor belt formed atleast partially of a plastic material movably carried on said frame andpresenting an upper horizontal surface along at least a portion of itslength; at least one movable platen carried on said frame for pressingsaid dough pieces against said upper surface of said belt; a beltsplicing hot press carried on said frame operatively engageable withsaid belt to splice together severed ends of said belt to form acontinuous endless belt.
 27. A press according to claim 26, includingbelt hold down clamps secured to said frame and engageable with saidupper surface of said belt.
 28. A press according to claim 26, whereinsaid belt splicing hot press comprises a vertically movable upper platenhaving a heating element therein and engageable with said upper surfaceof said belt and a stationary lower platen having a heating elementtherein and engageable with a lower surface of said belt.